Coordinated programmes

 

SPP 2402 – Greybox models to qualify coated tools for high performance machining

Short description:

The goal of the Priority Programme, SPP, 2402 is to generate new, fundamental insights into the mechanisms of wear and damage progression of coated tools in the cutting process with a geometrically defined cutting edge. The highly non-linear interactions of reality cannot be described completely deterministically by pure whitebox models due to necessary simplifying assumptions. Pure black box models, on the other hand, enable the modelling of complex correlations if the database is sufficiently large. However, physical correlations remain unconsidered in pure black box approaches. One approach is to combine white box and black box models in a grey box. In this way, both the explainability of the results and the ability of the models to deal with uncertainties can be increased.

The SPP 2402 is composed of 11 collaborative projects involving researchers from all over Germany. Expertise from the user side is contributed via an accompanying industry advisory board. It is expected that the use of grey box models will reveal new significances of cause-effect relationships. As a result, concrete decision-making aids are aimed at, which facilitate the selection of suitable tools for machining and enable tool manufacturers to make better tool recommendations for the concrete machining operation of a specific material.

Funding:	German Research Foundation (DFG)
Porject number:	SPP 2402
Duration:	July 1, 2023 to June 30, 2026

 

CoE-IoP - Cluster of Excellence „Internet of Production“

Short description:

The clusters of excellence establish competitive research facilities at German university locations and enable scientific networking and interdisciplinary collaboration. In this context, the Cluster of Excellence "Internet of Production (IoP)" at RWTH Aachen University pursues the digitalization of production technology. The cooperation of the various institutes and research facilities at the RWTH Aachen University combines expertise from production technology, computer science, materials science, economics, ergonomics and psychology to investigate interdisciplinary challenges. Real-time and secure data acquisition, the development of production engineering models and the creation of "digital shadows" are important components of Industry 4.0 and IoP. Furthermore, data analysis and machine learning methods are used to make predictions for error-free process control and for product development. The IOT is involved in the two subprojects WS-B1.I "Integrated Computational Materials Engineering" and WS-B2.II „Discontinuous Production“.

 

Funding:	German Research Foundation (DFG)
Porject number:	EXC 2023/1
Duration:	January 1, 2019 to December 31, 2025

 

SPP 2074 - Fluid-free lubrication systems under high mechanical load

Short description:

In the research program Fluid-free lubrication systems under high mechanical load - SPP 2074, the friction and wear mechanisms due to the formation of transfer layers in tribological systems are being studied when lubricating with solid lubricants. For this purpose, the first step is to determine the system-specific supply processes of the solid lubricant as a function of the operating conditions (including temperature, pressure, sliding speeds) in order to be able to determine the requirements for the availability of solid lubricant in the contact area to be lubricated. Depending on the operating conditions, the lubricant and the contact partners in the highly loaded contact, the transfer processes will be clarified on this basis. Here, a distinction can be made between physical and chemical transfer processes, which enable the most durable transfer possible. Physical adhesion mechanisms can occur through a mechanical "clamping" of solid lubricant components with the surface, chemical mechanisms can be based on physisorption and chemisorption. The understanding should subsequently be used to synthesis systems for the supply and transfer of solid lubricants in highly stressed contact conditions.

In the sub-project "Dry lubrication of spur gears - Contour-adapted coating design and tribological evaluation of performance limits", fluid-free lubricated spur gears that reliably withstand the high mechanical loads are designed. More detailed information is available here.

Funding:	German Research Foundation (DFG)
Porject number:	SPP 2074
Duration:	July 1, 2022 to June 30, 2025

 

SFB 1120 - Precision Melt Engineering

Short description:

The joining and coating of metallic components by means of melting processes is a particular challenge, since the flow and solidification of the melt strongly influence the component geometry and surface.

Thermal effects such as heat transfer and conduction as well as microstructural changes in the base material and filler metal also influence the degree of component precision. By increasing the precision of these melting processes, expensive finishing processes can be reduced, which is an economic advantage especially for larger high-precision components.

New approaches and technologies are required to influence melt phase dynamics and solidification. The goals of the Collaborative Research Center 1120 (SFB 1120) are the comprehensive understanding of these processes using the approach of "Precision Melt Engineering" as well as its derived measures to meet the precision requirements of melt-based manufacturing processes such as casting, joining, separating, additive manufacturing and coating. 11 research institutes of the RWTH Aachen University are working together in 22 sub-projects on the common goals. The IOT is working on the three sub-projects A5, A10 and A12.

The subproject A5 aims to increase the precision of brazing and TLP bonding. In order to achieve a targeted reduction of brittle phases and to improve the mechanical properties, brazing alloys are optimized and brazing processes are developed by means of current-assisted process control.

In subproject A10 the entire process of plasma spraying, starting with the plasma generator up to the coating build up is simulated. In this context, disturbance factors are identified and potential strategies for compensation are developed.

The subproject A12 is concerned with the development of thermally sprayed coatings that can be used to selectively control the heat flow on surfaces. For this purpose, casting tools are coated in order to realize a highly dynamic tempering during the casting process.

Funding:	German Research Foundation (DFG)
Porject number:	SFB 1120
Duration:	July 1, 2022 to June 30, 2026